International Journal of Metallurgical &

Materials Science and Engineering (IJMMSE)

ISSN(P): 2278-2516; ISSN(E): 2278-2524
Vol. 5, Issue 5, Oct 2015, 21-28
TJPRC Pvt. Ltd.

STUDIES ON Al6061/Al2O3 AND GRAPHITE HYBRID METAL MATRIX COMPOSITES

SUDINDRA S1 & C ANIL KUMAR2
1

P.G Student, Department of Mechanical Engineering, K.S.I.T, Bangalore, Karnataka, India

2

Professor, Department of Mechanical Engineering, K.S.I.T, Bangalore, Karnataka, India

ABSTRACT
Aluminum MMCs are preferred to other conventional materials in the fields of aerospace, automotive and marine
applications owing to their improved properties like high strength to weight ratio, good wear resistance etc. In the present
work an attempt has been made to synthesize metal matrix composite using 6061Al as matrix material reinforced with
ceramic Al2O3 and Graphite particulates using liquid metallurgy route in particular stir casting technique. The addition of
reinforcement alumina is maintained 10% as constant and the Graphite is varied as 3%, 6% and 9%. For each composite,
reinforcement particles were preheated to a temperature of 200 and then dispersed in steps of three into the vortex of
molten 6061Al alloy to improve wettability and distribution. Micro-structural characterization was carried out for the
above prepared composites by taking specimens from central portion of the casting to ensure homogeneous distribution of
particles. Hardness, tensile and wear properties of the prepared composite were determined before and after addition of
Al2O3 and Graphite particulates. Micro-structural characterization of the composites has revealed fairly uniform
distribution and some amount of grain refinement in the specimens. Further, the hardness, tensile strength and wear
resistance properties are higher in case of composites when compared to unreinforced 6061Al matrix.

KEYWORDS: MMCs, Al2O3 Particulates, Graphite, Al 6061, Stir-Casting

INTRODUCTION
Metalmatrix composites (MMCs) are most promising materials in achieving enhanced mechanical properties
such as: hardness, Youngs modulus, yield strength and ultimate tensile strength due to the presence of micro-sized
reinforcement particles into the matrix. Aluminum-matrix composites (AMCs) reinforced with discontinuous
reinforcements are finding increased use in automotive, military, aerospace and electricity industries because of their
improved physical and mechanical properties. Among Al-alloys, 6061Al-alloy is widely used in engineering applications
such as transport and construction sectors where superior mechanical properties like tensile strength, hardness etc., are
essentially required.
The mechanical properties of MMCs are very sensitive to the method of processing being used. Considerable
improvements may be achieved by applying science-based modeling techniques to optimize the processing procedure.
Several techniques have been employed to prepare the composites including powder metallurgy, melt techniques and
squeeze casting. However, powder metallurgy appears to be the preferred process in view of its ability to give more
uniform dispersions. Hot extrusion is generally used as post-treatment to take the advantages of applying compressive
forces and high temperatures, simultaneously [1] [2] [3].
Although powder metallurgy produces better mechanical properties in MMCs, liquid state processing has some
important advantages. They are as: better matrix-particle bonding, easier control of matrix structure, simplicity, low cost of
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Sudindra S & C Anil Kumar

processing, nearer net shape and the wide selection of materials. Liquid state fabrication of MMCs including two methods
which depend on the temperature at which the particles are introduced into the melt. In melt stirring process, the particles
are incorporated above the liquidus temperature of the molten alloy, while in compo-casting method the particles are
incorporated at the semi solid slurry temperature of the alloy. In both processes, the vortex is used for introducing
reinforcement particles. However, the melting process has two major problems firstly, the ceramic particles are generally
not wetted by the liquid metal matrix, and secondly, the particles tend to sink or float according to their density relative to
the liquid metal. Wettability can be defined as the ability of a liquid to spread on a solid surface and it represents the extent
of intimate contact between liquid and solid. Consequently, it results in poor dispersion of the ceramic particles, high
porosity and low mechanical properties of the composite The aim of present study is to synthesize 6061Al- Al2O3
particulate MMC by stir casting method. In order to improve wettability and distribution of reinforcing particles a novel
three stage mixing combined with preheating of the reinforcing particles is being adopted and also to investigate the effects
of different factors such as:

Weight percentage of the particles

Fabrication process on the microstructure, mechanical and wear properties of the composites.

EXPERIMENTAL DETAILS
The following section highlights the material, its properties and methods of composite preparation and testing.
Materials Used
The matrix material for the present study is Al6061. Al2O3 and Graphite is used as reinforcement material in the
preparation of composites. The chemical composition of matrix material is as shown in Table1. The particles size of the
reinforcing material was about 80-100 m. Table 2 gives the properties of Matrix and Reinforcing materials used in the
present study taken from the literature.
Table 1: The Chemical Composition of Al6061 Alloy by wt%
Elements
Percentage

Si
0.43

Fe
0.7

Cu
0.24

Mn
0.139

Ni
0.05

Pb
0.24

Zn
0.25

Ti
0.15

Sn
0.001

Mg
0.802

Cr
0.25

Al
Balance

Table 2: The Properties of Matrix and Reinforcing Materials Used in the Study
Material/
Properties
Matrix 6061 Al
Reinforcement
Al2O3 Particle
Reinforcement
Graphite particle

Density
gm/cc
2.7

Hardness
(HB500)
30

Strength (Tensile/
Compressive) MPa
115 (T)

Elastic
Modulus GPa
70-80

3.69

1175

2100 (C)

300

1.92

1021

90 (T)

14

Preparation of Composites
The liquid metallurgy route (stir casting technique) has been adopted to prepare the cast composites as described
below. Preheated Al2O3 and Graphite particles of laboratory grade purity of particle size 80-100m were introduced into
the vortex of the molten alloy after effective degassing using solid hexachloroethane (C2Cl6). Before introducing
reinforcement particles into the melt they were preheated to a temperature of 2500C. The extent of incorporation of Al2O3
and Graphite particles in the matrix alloy was achieved in steps of 3. i. e Total amount of reinforcement required was
Impact Factor (JCC): 3.3529

Index Copernicus Value (ICV): 3.0

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Studies on Al6061/Al2O3 and Graphite Hybrid Metal Matrix Composites

calculated and is being introduced into melt 3 times rather than introducing all at once. At every stage of before and after
introduction of reinforcement particles, mechanical stirring of the molten alloy for a period of 10 min was achieved by
using Zirconia-coated steel impeller. The stirrer was preheated before immersing into the melt, located approximately to a
depth of 2/3 height of the molten metal from the bottom and run at a speed of 200 rpm. A pouring temperature of 7500C
was adopted and the molten composite was poured into permanent cast iron moulds. Thus composites are made with base
material Al6061, Al6061+10% Al2O3, Al6061+10% Al2O3+Gr 3% and by varying Graphite up to 9% in the interval of 3%,
were obtained in the form of cylinders of diameter 12.5mm and length 125mm [4], [5].
Testing of Composites
To study the microstructure of the specimens the central portion of the casting was cut by an automatic cutter
device. The specimen surfaces were prepared by grinding through 300, 600 and 1000 grit papers and then by polishing
with 3 m diamond paste. Microscopic examination of the composites was carried out by optical microscopy. To
investigate the mechanical behavior of the composites the hardness and tensile tests were carried out using Zwick and
computerized uni-axial tensile testing machine as per ASTM standards, Figure 1. represent the dimensions of the mould
and specimen used for tensile studies.
The Micro-Vickers hardness values of the samples were measured on the polished samples using diamond cone
indentor with a load of 20N. Hardness value reported is the average value of 100 readings taken at different locations on
the polished specimen. For tensile results, test was repeated three times to obtain a precise average value.

(a)

(b)

Figure 1: The Details of (a) Dimensions of the Tensile Specimen (b) Mould for Producing Composites

RESULTS AND DISCUSSIONS

Fabrication of metalmatrix composites with alumina particles by casting processes is usually difficult because of
the very low wettability of alumina particles and agglomeration phenomena which results in non-uniform distribution and
weak mechanical properties. In the current work, Al6061 aluminum alloy matrix composites with micro size alumina and
Graphite particles were produced by stir casting method [6]. The magnitude of alumina powder used in the composites is
10% and Graphite starting from is 3%, 6% and 9% . The optical micrographs of the 6061-Al alloy with 10wt. % alumina
particulates and 3%, 6%, 9% of varying Graphite percent were shown in Figure 3(a-e).

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Sudindra S & C Anil Kumar

(a)

(b)

(c)

(d)

(e)
Figure 2 a-e: The Optical Microphotographs (a) As-Cast (b) with 10% Al2O3
(c) with 10% Al2O3 +3%Gr (d) with 10% Al2O3 +6%Gr (e) with 10% Al2O3 +9%Gr
The microstructure of as cast 6061Al and 6061Al with 10 wt% Al2O3 with varying Graphite percentage are
represented in Figure 2a-e. The microstructure of the prepared composites contains primary -Al dendrites and eutectic
silicon, while Al2O3 and Graphite particles are separated at inter-dendritic regions and in eutectic silicon. The stirring of
melt before and after introducing particles has resulted in breaking of dendrite shaped structure into equiaxed form, it
improves the wettability and incorporation of particles within the melt and also it causes to disperse the particles more
uniformly in the matrix. Figure 2b-e reveals the distribution of alumina particles in different specimens and it can be

Impact Factor (JCC): 3.3529

Index Copernicus Value (ICV): 3.0

Studies on Al6061/Al2O3 and Graphite Hybrid Metal Matrix Composites

25

observed that there is fairly uniform distribution of particles and also agglomeration of particles at few places were
observed in both the composites reinforced with 9wt.% Graphite. The microphotographs also indicate that the Al2O3 and
Graphite particles have tendency to segregate and cluster at inter-dendritic regions which are surrounded by eutectic silicon
(Figure 2be). Further, the micrographs show that grain size of the reinforced composite (Figure 2.a-e) is smaller than the
alloy without alumina particles (Figure 2a) because, Al2O3 and Graphite particles added to melt also act as heterogeneous
nucleating sites during solidification.
Hardness Measurement
The micro hardness tests conducted on Al 6061 and Al6061 composite containing 10% of Al2O3 and 3%, 6% and
9% of varying Graphite particles are prepared and the results are represented in Figure3. The Micro-Vickers hardness were
measured on the polished samples using diamond cone indenter with a load of 100g and the value reported is average of
100 readings taken at different locations. A significant increase in hardness of the alloy matrix can be seen with addition of
Al2O3 particles. A hardness reading showed a higher value of hardness indicating that the existence particulates in the
matrix have improved the overall hardness of the composites. This is true due to the fact that aluminum is a soft material
and the reinforced particle especially ceramics material being hard, contributes positively to the hardness of the
composites. The presence of stiffer and harder Al2O3 reinforcement leads to the increase in constraint to plastic
deformation of the matrix during the hardness test. Thus increase of hardness of composites could be attributed to the
relatively high hardness of Al2O3 itself. Though adding Graphite makes material ductile but the hardness does not decrease
below the base material.

Figure 3: Showing the Variation in VHN for all the Mentioned Compositions
Tensile Properties
To investigate the mechanical behavior of the composites the tensile tests were carried out using computerized
uni-axial tensile testing machine as per ASTM standards. Three test specimens were used for each run. From the test it is
inference that the improvement in ultimate tensile strength in base matrix with 10% alumina is maximum, this is due to the
fact that alumina is a hardest ceramic which on reinforcement forms a stronger composite. i.e. the load applied is shared
between aluminum base matrix and alumina, as said above when the load is shared by hardest particle alumina, it resists
deformation resulting in higher stress withstanding capability. In further as the Graphite percentage is varied ductility

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Sudindra S & C Anil Kumar

increases which also contribute in higher plastic region and hence the increase in ultimate and yield strengths are
represented in Figure 4.
Table 3: The Results of Tensile Test Specimens
Sl
No.

Composition

1
2
3
4
5

Al6061
Al6061+10wt%Al2O3
Al6061+10wt%Al2O3+3%Gr
Al6061+10wt%Al2O3+6%Gr
Al6061+10wt%Al2O3+9%Gr

Tensile
Strength
(MPa)
128
164
153
158
160

Yield
Strength
(MPa)
116
152.89
138.41
140.38
142.37

%Improvement
in Tensile
Strength
28.12
19.53
23.43
25

Figure 4: The Variation in Tensile Strength for Different Compositions of Al6061 with Al2O3 and Graphite Particles
Wear Properties
Wear is a process of material removal phenomenon [7] [8]. The prepared 6061Al with10% Al2O3 and varying
weight percentage of Graphite composites were subjected to wear test under dry sliding condition. The test was conducted
on 8mm diameter and 25mm long cylindrical specimens against a rotating En-32 steel disc. The tangential friction force
and wear were monitored with the help of electronic sensors. These two parameters were measured as a function of load
and sliding distance. For each type of material, tests were conducted at 20N nominal load and varying sliding speed at
400rpm and 600rpm, wear tests were carried out at room temperature without lubrication and the Wear results are
represented in Figure 5.

Impact Factor (JCC): 3.3529

Index Copernicus Value (ICV): 3.0

27

Studies on Al6061/Al2O3 and Graphite Hybrid Metal Matrix Composites

Figure 5: The Wear Results for the above Mentioned Compositions at 400 and 600 rpm

CONCLUSIONS

From optical microscopy results it is found that addition of magnesium at 0.1 ratio to the reinforcement increases
the wettability and dispersion of the reinforcement particles.

Tensile strength of prepared composites is higher in case of composites, when compared to cast 6061Al.

Addition of 10wt% Al2O3 increases the tensile strength considerably with respect to base matrix Al6061. Whereas
the addition of Graphite particulates doesnt vary the tensile strength much with respect to Al2O3 added
composition.

Hardness number of the prepared composites is higher than the base 6061Al-alloy.

Addition of 10wt% Al2O3 increases hardness considerably, whereas the addition of Graphite particulates
decreases the hardness and increasing in ductility, The cumulative effect results higher than the Al6061 alloy.

Addition of 10wt% Al2O3 decreases the wear rate compared to base Al6061 alloy. The Cumulative effect of
10wt% Al2O3 and Graphite particulates with varying percentage further decreases the wear rate.

As the addition of Al2O3/Graphite particulates increases tensile strength and is decreasing the wear rate, these
composites can be used for journal bearings and antennas in aircrafts.

REFERENCES
1.

G. B. Veeresh Kumar, C. S. P. Rao, N. Selvaraj, M. S. Bhagyashekar , Studies on Al6061-SiC and Al7075Al2O3 Metal Matrix Composites, Journal of Minerals & Materials Characterization & Engineering, Vol. 9, No.1,
pp. 43-55, 2010

2.

Rakesh Kumar Yadav, Nabi Hasan, and Ashu Yadav ,Studies of mechanical properties of Al based cast
composites, IJCSMS International Journal of Computer Science and Management Studies, Vol. 11, Issue 02,
Aug 2011

3.

Martin, J. Rodriguez, J. Llorca - Elsevier, Temperature effects on the wear behavior of particulate reinforced Albased composites, WEAR, volume 255

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Sudindra S & C Anil Kumar

4.

S. Gopalakrishnan, N. Murugan - Elsevier, Production and wear characterization of AA 6061 matrix titanium
carbide particulate reinforced composite by enhanced stir casting method, Materials & Design, Volume 32, Issue
7, August 2011

5.

Go Wu, Keyna OReilly and Mariana Gallano, Characterization of casting defects in aluminium alloys,
Advanced materials research, Vol 430 432, Trans Tech Publications, Switzerland.

6.

K.M. Shorowordi, T. Laoui, A.S.M.A. Haseeb , J.P. Celis, L. Froyen Elsevier, Microstructure and interface
characteristics of B4 C, SiC and Al2O3 reinforced Al matrix composites: a comparative study, Journal of
Materials Processing Technology, Vol 142, 2003

7.

S. Mahdavi and F. Akhlagi ,Effect of the Graphite content on the tribological behavior of Al/Gr and Al/30Sic/Gr
composites processed by IN Situ Powder Metallurgy (IPM) Method , Springer Science + Business Media, LLC
2011

8.

Basavarajappa S. and Chandramohan G., Wear studies on metal matrix composites- Taguchi approach, Journal
of Material Science and Technology, 2005, 21(6), 845- 850.

Impact Factor (JCC): 3.3529

Index Copernicus Value (ICV): 3.0